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Fundamentals of Graphics Communication, 5th Edition
Fundamentals of Graphics Communication, 5th Edition
Fundamentals of Graphics Communication, 5th Edition
CHAPTER
Auxiliary Views
6
For the vision of one man lends not its wings
to another man.
—Kahlil Gibran
There are times when one of the six principal views will
not completely describe an object. This is especially true
when there are inclined or oblique planes or features on an
object. Refer to Chapter 5 for definitions for inclined and
oblique planes. For these cases, a special orthographic
view called an auxiliary view can be created. This chapter
describes how to create auxiliary views for objects that
cannot be represented clearly by the six principal views.
Also described is the use of auxiliary views to solve
spatial geometry problems, such as the point and true-length
views of lines and edges, and the true-size views of planes. 311
324 Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
312 CHAPTER 6
6.1 Auxiliary View Projection Theory sheet. Then, position the clear plastic sheet in front of and
An auxiliary view is an orthographic view that is pro- parallel to the inclined surface. Trace the outline of the
jected onto any plane other than one of the six principal inclined surface on the clear plastic sheet. Use a ruler to
views. Figure 6.1A shows three principal views of an measure the perimeters of the two views of the inclined sur-
object. Surface ABCD is an inclined plane and therefore is face. Explain why the distances are not equal.
never seen in true size or shape in any of these views. In a
multiview drawing, a true size and shape plane is shown
only when the line of sight (LOS) used to create the view
6.1.1 Fold-Line Method
is perpendicular to the projection plane. To show the true
size and shape of surface ABCD, an auxiliary view can be In Figure 6.2, the object is suspended in a glass box to show
created by positioning a line of sight perpendicular to the the six principal views, created by projecting the object
inclined plane, then constructing the new view (Fig- onto the planes of the box. The box then is unfolded, result-
ure 6.1B). Two methods of creating auxiliary views are the ing in the six principal views. However, when the six views
fold-line method and the reference plane method. These are created, surface ABCD never appears true size and
are discussed in the following sections. shape; it always appears either foreshortened or on edge.
Figure 6.3 shows the object suspended inside a glass
box, which has a special or auxiliary plane that is parallel
to inclined surface ABCD. The line of sight required to
Practice Exercise 6.1 create the auxiliary view is perpendicular to the new pro-
jection plane and to surface ABCD. The auxiliary plane is
On a flat surface, place a small object that has an inclined
perpendicular to and hinged to the frontal plane, creating a
plane, such as the part shown in Figure 6.1. Determine the
fold line between the front view and the new auxiliary
principal views for this object for a three-view multiview
view.
drawing. Position a rigid, clear plastic sheet in front of and
In Figure 6.4, the auxiliary glass box is unfolded, with
parallel to a principal view such that the inclined plane
the fold lines between the views shown as phantom lines.
appears foreshortened. Using a water-soluble color marker,
In the auxiliary view, surface ABCD is shown true size
trace the outline of the inclined surface on the clear plastic
and shape and is located at distance M from the fold line.
B
B C B C AUXILIARY
Inclined VIEW
Inclined plane plane
TRUE
A SHAPE
AND C
SIZE
t
gh
A D
si
A D
of
ne
D
Li
D, C D C D C
D, C
(A) (B)
w
ie
A
V
p
To
B
A,B
D
A
Top View
C
D
D B ,C
A, B
A
C Back View Left Side View Front View Right Side View
L D wei
tfe V kca
iS D,C
ed B
iV
B
we
B
to
Fro
ot
A
n
m
t Vi
V
Bottom View
ei
ew
w
D
iew
eV
Sid
ht
Rig
Figure 6.2 Object in glass box and resulting six views when the box is unfolded
w
B
ie
V
w
p
Vie B C
To
Top View
C
A
a ry
xili
D
Au
L B
B ine of
A, Si ght A D
B B
A
M A C
ew
A
C
Vi
ry
C
DD ,C
ilia
M
x
Au
B D
A, D B
A
L wei
tfe C V
B
we D w
D,C
e Vie
Sid
D
ht M
Rig D C
B
Fro
to
n
ot
t Vi
m
ew
V
Figure 6.3 Object in glass box with special auxiliary Figure 6.4 Unfolding the glass box to create an auxiliary
plane view of the inclined plane
326 Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
314 CHAPTER 6
The line A–D in the top view and right side view is also
Top View
ew
A D Vi 6.1.2 Reference Plane Method
M
ry
A C
ilia
M
is simply a variation of the fold-line method. The refer-
D ence plane method is a technique that locates a plane rela-
Fold Lines tive to the object, instead of suspending the object in a
A B glass box. This single plane then is used to take measure-
M ments to create the auxiliary view. In Figures 6.3 and 6.4,
D C the frontal plane of projection is the frontal fold line in the
multiview drawing that is used to construct the auxiliary
Front View Right Side View
view. This fold line is used as a reference plane for trans-
ferring distances from the top view to the auxiliary view.
The reference plane can be positioned anywhere relative
Figure 6.5 Object distance from fold line to the object, as shown in Figure 6.6. In Figure 6.6A, the
Object distance from the frontal plane determines the distance reference plane coincides with the front surface of the ob-
from the fold lines in the right side, auxiliary, and top views. ject, so it appears on edge in the top and auxiliary views
and is drawn as a line. The reference line then is used to
take measurements that are transferred from the top view
to the auxiliary view.
The advantage of the reference plane method is that, if
positioned correctly, it can result in fewer measurements
Reference
Reference Reference Plane
Plane Plane
1 H
P 1 P
P
A A
H A A
H 1
A P
P P
A A
A
A
A
A
A
P R PR PR
(A) (B) (C)
when constructing auxiliary views. When using reference auxiliary view from an existing auxiliary view. Therefore,
planes or fold lines always remember the following: auxiliary views first are classified as: primary, secondary,
or tertiary (Figure 6.7).
1. Reference or fold lines always are drawn perpen-
dicular to the projection lines between the views. A primary auxiliary view is a single view projected from
2. Transfer measurements always are taken parallel one of the six principal views.
to the projection lines and perpendicular to the ref- A secondary auxiliary view is a single view projected
erence or fold lines. from a primary auxiliary view.
3. Reference planes always appear on edge as lines A tertiary auxiliary view is a single view projected from
in the views adjacent to the central view but never a secondary or another tertiary auxiliary view.
in two adjacent views.
Auxiliary views also are classified by the space
4. Distances from the object to the reference or fold
dimension shown in true size in the primary auxiliary
lines in the auxiliary view and the measuring view
view. For example, the auxiliary view shown in Fig-
are the same.
ure 6.5 is classified as a depth auxiliary because the depth
dimension is shown true length. Auxiliary views pro-
6.2 Auxiliary View Classifications jected from the top view are classified as height auxiliary
Auxiliary views are created by positioning a new line of views (Figure 6.7). Auxiliary views projected from a
sight relative to the object. It is possible to create any profile view are classified as width auxiliary views. (See
number of successive auxiliary views, including a new Figure 6.10 on page 319.)
Primary
Auxiliary View
D1
X Z
Secondary
C1 LOS Auxiliary View
Y
E1 A1
Y
S
LO
B1 C2
F1 D2
DT CT
B2
A2
ET FT
1 1
2
T F2 E2
AT BT
2
T 3
F
LOS
B3
X
C3 Z
A3
AF DF BF CF
F3
D3
Figure 6.7 E3
Primary, secondary, and tertiary auxiliary views Tertiary
The line of sight (LOS) determines the direction of the projection lines used in each auxiliary view. Auxiliary View
328 Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
316 CHAPTER 6
6.2.1 Reference or Fold-Line Labeling Conventions planes. Since the horizontal projection plane contains the
The labeling convention for the reference or fold lines in top view, the alternate labeling would be H–F and H–1.
auxiliary view construction can vary. However, the labels The fold line located between the primary (i.e., first)
normally are descriptive in nature. For the example in Fig- and secondary auxiliary views is labeled 1–2. Similarly,
ure 6.7, the fold line located between the front and top the fold line between the secondary and tertiary auxiliary
views is labeled T–F, where the F means front and the T views is labeled 2–3.
means top. The fold line located between the top and the
6.2.2 Depth Auxiliary View
primary auxiliary view is labeled T–1, where T is for the
top view and 1 represents the first auxiliary view. Alterna- A depth auxiliary view is projected from the front view,
tively, the fold lines can be labeled by the projection and the depth dimension is shown true length. Figure 6.8
Auxiliary
Plane
Y H
B
1
A
Lin
X eo
D
X B f Si
ght
(LO
H
F Y A S)
e
Tru ze 1
Si
C P
A, B D B
A
C
Y
D D
F P
B C B C B C
A D A D A D
S
X
LO
1 H ,C H
1
F F F F 1
F
A, B A, B A B A,B A B
A B
D D D C
D, C C D, C C D, C
F P F P
X
B C B C B C
A A B A D B
D X D
C Y Y C A C
H H H
1
F F F F
1 1 D
X F
F
A,B A B A,B A B A,B A B
D D D
C D,C C D C
D,C
X F P F P
F P
Step 4 Step 5 Step 6
Figure 6.8 Constructing a depth auxiliary view to determine the true size and shape of the inclined surface
Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill 329
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
shows an auxiliary view that is projected from the front Only the inclined plane has been drawn in the auxiliary
view of an object, using the fold-line method. Since plane view; the rest of the object is not represented. When only
ABCD is an inclined plane in the principal views, an aux- the feature of interest is drawn in an auxiliary view and not
iliary view is needed to create a true-size view of that the whole object, the view is called a partial auxiliary
plane. A depth auxiliary view of plane ABCD is created as view. Most auxiliary views will be partial. Also, hidden
described in the following steps. features are not shown unless absolutely necessary.
318 CHAPTER 6
H
F H
P
H
X 1
Y Y X
Y
D A
X True
Size
C B
A,B A A A
B A,B B A,B B
D A D A X D A
C B C B C B
Step 1 Step 2 Step 3
H P H P H P
A A A
A,B B A,B B A,B B
C C C
C B C B C B
Step 4 Step 5 Step 6
H
1 Y
H
P
X
S) B Y
(LO
ight
of S Tru A
Line Size e
1C
F D
Y
X
F P
C B C B C B
X D
LO
D A D A
A
S
H H
P P
1 1 1
P P P
X
A,B A,B B A A,B
B A B A
C B C B C B
F
B
B B
X D D D
A A A
Y A
H H H
D C
P P P
1 1 1
P Y P D P
X
A A,B B A A,B B A,B
B A
D,C C D,C D,C
C D D C D
P
F P L F P
Step by Step: Constructing a Width Auxiliary View a distance X from the rear edge of the top view. The dis-
Step 1. Given the front, top, and left side views, draw fold tance from fold line H–P to the top view must equal the
line P–1 using a phantom line parallel to the edge view of distance from fold line F–P to the front view. Draw parallel
the inclined surface. Place the line at any convenient dis- projectors between each view, using construction lines.
tance from the profile view. Step 3. Project the length of the inclined surface from the
Step 2. Draw fold line F–P between the front and profile profile view to the auxiliary view, using construction lines.
views, perpendicular to the projectors between the views The projectors are perpendicular to the edge view and pro-
and at a distance X from the left edge of the front view. jected well into the auxiliary view from corners A,B and D,C.
Draw fold line H–P between the top and profile views, Step 4. Transfer the width of the inclined surface from the
perpendicular to the projectors between the views, and at front view by first measuring the perpendicular distance
332 Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
320 CHAPTER 6
Half
from fold line P–F to the left side of the front view. For this Auxiliary
example, point B is measured at distance X from fold I
line P–F and is then transferred to the auxiliary view F
along the projectors perpendicular to fold line P–1. From
point B in the auxiliary view, draw a line perpendicular to
the projectors. H
Step 5. Width dimension Y is then transferred from the F
front view in a similar manner, measuring the perpendic-
ular distance from fold line P–F to point A (or D) of the
front view and transferring this distance to the auxiliary
view along the projectors perpendicular to fold line P–1.
From the transferred point A in the auxiliary view, draw a
line perpendicular to the projectors.
Step 6. Darken lines A–B and C–D to show the true size of
the inclined surface to complete the partial auxiliary view.
6.2.7 Curves
Figure 6.13 shows a cylindrical part that is cut by an in-
clined plane. The resulting surface is an ellipse that only
H
Full
I
Auxiliary can be shown true size and shape with an auxiliary view.
The process for drawing curves in an auxiliary view is
Partial
described in the following steps.
H
Auxiliary
I
1
Major Axis
F
11 11
1
1,2 2
3
3,4 5 4
7 6
5,6
7,8 9 8
9,10 10
12 12
F R F R F R
Step 1 Step 2 Step 3
1
1
Minor Axis
2
11
11
F
F
4
4
6
6
8
8
1
1
10
10
3
3
5
5
12
12
7
7
9
9
11 11 11 11
1 2 1 2
1,2 1,2
3,4 3 4 3,4 3 4
5 6 5 6
5,6 5,6
7,8 7 8 7 8
7,8
9,10 9 10 9,10 9 10
12 12 12 12
F R F R
Step 4 Step 5
Step 2. Locate the edge view of the reference plane in the sions from the right side view to the projectors in the
auxiliary view by drawing a line parallel to the edge view auxiliary view.
of the ellipse and at any convenient distance from that Step 5. Using a French curve, connect the points to create
edge. The reference plane will coincide with the location the true size and shape of the curved surface.
of the major axis of the ellipse. The location of the refer-
ence plane should leave sufficient room for the auxil- 6.2.8 Auxiliary Views Using CAD
iary view to be plotted without running into any of the
Auxiliary views can be created with 2-D CAD using the
multiviews.
same basic steps outlined in this chapter. Commands such
Step 3. Plot points along the circumference of the circle in
as PARALLEL, PERPENDICULAR, and SNAP are use-
the right side view, and project these points onto the
ful in creating auxiliary views. Some 2-D CAD systems
edge view of the ellipse in the front view. Number the
can rotate their grids so that they are parallel to the projec-
points to assist in plotting the corresponding points in
tors, which makes the creation of auxiliary views much
the auxiliary view.
easier. With 3-D CAD, it is possible to create an auxiliary
Step 4. Project the points from the ellipse edge view in the
view by changing the viewing direction to be perpendicu-
front view through the reference plane in the auxiliary
lar to the inclined or oblique surface of interest. Many 3-D
view. The projectors should be perpendicular to the
CAD systems allow you to define this view by selecting
edge view and the reference plane. The projector from
the surface or edges that lie in the same plane. This view
the point for the center line of the cylinder in the front
can be saved and then added to the multiview drawing of
view coincides with the minor axis of the ellipse in the
the part. When an auxiliary view is created from a 3-D
auxiliary view. Measure and transfer the depth dimen-
model, a full auxiliary view can be created in a much
shorter time than when using traditional means.
334 Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
322 CHAPTER 6
1
line of sight A–B also is shown in true length in view 1.
Step 3. Find the point view of line A–B by drawing a pro-
2 F 1
jector parallel to it in view 1. Project all points in view
A A
1 parallel to the projector for line A–B, into a new auxiliary
view called view 2. Draw a new reference plane perpen-
2,1
2 1 dicular to the projectors and label it 1–2.
Step 4. In the top view, measure the perpendicular dis-
tances from reference plane H–1 to each point. Transfer
these distances along the projectors in view 2 from refer-
ence plane 1–2. Number each point in the new view and
connect them with lines. This creates the desired view in
the specified direction, that is, the direction of the arrow
AB. The line of sight A–B will appear as a point in this
view. Lines 1–6, 6–7, and 6–10 are hidden features and
Figure 6.14 are represented as dashed lines.
Reverse construction technique
336 Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
324 CHAPTER 6
6
1 Primary
W
S
LO
7
1 2
X 8
1 10 3
H
H 9,5
4
B
Z
T.
Y
L
9 8,7 10,6 9 8,7
.
10,6 A
B B
5,1 4 3,2 A 5,1 4 3,2 A
H Top H Top A
F F
A X B
5,10 4,9 5,10 4,9 A
Y
B B
W
3,8 3,8 Z
Step 1 Step 2
6
6 1 Primary
1 Primary
7
7 1 10 2
2 8
10 H
8 9,5 3
1 4
9,5 3
H
4 N
M B
B 1
T.
9 8,7
L
2
.
T.
B
.
A
7
A 8
B 2
B AB
5,1 4 3,2 A
5,1 4 3,2 A H Top A,B 3
1 6
H Top F M 9
2
LO
F 5,10 4,9 A N 1
S
5,10 4,9 A 10
B 4
B 3,8
Secondary 5
3,8
1,6 2,7
1,6 2,7 Front
Front
Step 3 Step 4
6.3.3 Dihedral Angles therefore, a point view of that line can be found by creat-
A dihedral angle is the angle between two planes. Deter- ing an auxiliary view using projectors parallel to that view
mining the true measurement of a dihedral angle is a com- of the line.
mon application for auxiliary views. To draw and measure Step 2. Draw the fold line H–1 perpendicular to line 1–2 at
the angle between two planes, create a point view of the any convenient distance from the top view. Draw the fold
line of intersection between the two planes. line H–F between the front and top views such that it is
perpendicular to the projectors between the two views,
at any convenient distance.
Step by Step: Determining the True Measurement Step 3. Measure the perpendicular distances in the front
of a Dihedral Angle view from fold line H–F and transfer those distances to
The following steps describe how to find the true angle the projectors in the auxiliary view, measuring from fold
between surfaces A and B in Figure 6.16. line H–1. This creates a new view of the object, and the
Step 1. Line 1–2 is the line of intersection between sur- true angle between planes A and B can be measured in
faces A and B. Line 1–2 is true length in the top view; this new view.
Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill 337
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
1 1 1
B B B H
A A A I
H True Angle
I
2 2 2 Auxiliary
View
LO
S
2,1
Not a
True Angle
H H
F F
D D
6.3.4 Successive Auxiliary Views: True Size of Oblique Step by Step: Constructing Successive Auxiliary Views
Surfaces to Determine the True Size of an Oblique Surface
Step 1. For the first auxiliary view, place the line of sight par-
An infinite number of auxiliary views can be created from
allel to a true-length line of the oblique surface in one of the
any given view. In Figure 6.17 (on the next page), the arrows
principal views. For this example, side A–B of the oblique
surrounding the primary auxiliary view indicate just some
triangular surface ABC is a true-length line in the top view.
of the lines of sight that can be used to create other auxiliary
Draw a projector from point B, parallel to line A–B. Draw a
views, and with each new auxiliary view, others can be cre-
line parallel to this projector from point C. Draw reference
ated. Successive auxiliary views are multiple auxiliary
plane H–1 perpendicular to these projectors. Place an-
views of an object created by projecting from previous aux-
other reference plane H–F between the front and top views,
iliary views. Figure 6.17 shows the front and top principal
perpendicular to the projectors between the two views.
views and three successive auxiliary views of an object.
In the front view, measure the perpendicular distances
Successive auxiliary views can be used to draw an
from reference line H–F to points A and C. Transfer these
oblique surface in true size and shape. The first step is to
measurements to the auxiliary view, measuring along the
construct a new view from one of the principal views, par-
projectors, from reference line H–1. This will produce an
allel to a true-length line of the oblique plane. In this new
edge view of the oblique surface, labeled B, A–C.
view, the oblique surface will be an edge. A secondary
Step 2. Create a secondary auxiliary view by projecting
auxiliary view is then created, perpendicular to projectors
lines from points A, B, and C perpendicular to the edge
from the edge view of the oblique surface, and the sec-
view of the surface. Draw a reference line 1–2 perpendic-
ondary view shows the true size and shape of the surface.
ular to these projectors. Measure the perpendicular dis-
The following steps describe how to create a true-size
tances from reference line H–1 to points B,A, and C in
view of the oblique surface in Figure 6.18 (on page 327).
338 Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
326 CHAPTER 6
Secondary
6 1
10 5
Primary 6 9 4
1 7 2
3
7 8
10
8 2 1
2
9,5
3 2 3
4 1 2
3 7 4 5
6
10,6 9 8,7 8
1
9 10
H Tertiary
5,1 4 3,2
Top
H
F
5,10 4,9
3,8
1,6 2,7
Front
the top view. Transfer these measurements to the sec- 6.4 Summary
ondary auxiliary view, measuring along the projectors,
from reference line 1–2. Darken lines A–B, B–C, and C–A Auxiliary views are a type of orthographic projection used
to produce a true-size view of the oblique surface ABC. to determine the true size and shape of inclined and
oblique surfaces of objects. Normally, auxiliary views are
Practice Exercise 6.2 projected from existing principal views. However, auxil-
Using an object with an oblique surface, look at the object
iary views also can be drawn first and then used to create
from the three principal views. How is the oblique surface
a principal view. This is done when a true measurement
seen in the three views? Is it ever seen in true size? Is it ever
only can be obtained by an auxiliary view and that mea-
seen as an edge view? Rotate the object to get an edge
surement is needed in order to create a principal view.
view of the oblique surface. Then rotate the object 90 de-
This technique is called reverse construction. Any number
grees about one of the edges bounding the oblique surface
of auxiliary views of an object can be created. Successive
to obtain a true-size view of the surface.
auxiliary views can be created by projecting from an ex-
isting auxiliary view.
Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill 339
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
A
C
TRUE
SIZE
A
C
B
B
1 2
1 1
H B,A H B,A
Y C C
W IEW
EDGE VIE EDGE V
B
X B
TH B TH
ENG ENG
L L
UE UE
TR TR A C
A C A C
H H
F F
Y
A B A B
C C
Step 1 Step 2
Figure 6.18 Constructing successive auxiliary views to determine the true size of an oblique surface
Goals Review
1. Create auxiliary views of inclined planes. Sec- 3. Explain auxiliary view projection theory. Section 6.1
tions 6.2.2, 6.2.3, and 6.2.4 4. Define primary, secondary, and tertiary auxiliary
2. Use reference planes and fold lines when creating views. Section 6.2
auxiliary views. Sections 6.1.1 and 6.1.2
340 Bertoline−Wiebe: 6. Auxiliary Views Text © The McGraw−Hill
Fundamentals of Graphics Companies, 2007
Communication, Fifth
Edition
328 CHAPTER 6
Historical Highlight
Early Technical Drawings Become More Refined
5. Define width, height, and depth auxiliary views. Sec- 10. Use auxiliary views for reverse construction. Sec-
tions 6.2.2, 6.2.3, and 6.2.4 tion 6.3.1
6. Create successive auxiliary views. Section 6.3.4 11. Create a view in a specified direction using auxiliary
7. Solve dihedral angle problems. Section 6.3.3 views. Section 6.3.2
8. Create a partial auxiliary view. Section 6.2.5 12. Understand the difference between 2-D methods and
9. Plot curves in auxiliary views. Section 6.2.7 3-D CAD in creating auxiliary views. Section 6.2.8
(7)
330 CHAPTER 6
332 CHAPTER 6
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4
Design in Industry
Concept to Victory in 7 Months
This case study describes the design of a special bike frame Sagan used the new integrated paint function in Studio
designed for Lance Armstrong using 3-D modeling and to sketch out different 3-D views of the bike’s frame over
CAD. In this case study, you will see examples of how the Pro-E centerlines created by Trek Lead Engineer Doug
design process is used and the importance of 3-D modeling Cusack. After concepts were reviewed and a direction
to shorten the design time from 12 months to 7 months. decided, a complete 3-D digital frame was created.
Advanced Concept Group modelmakers used the digital
Designing a Winning Tour de France Bike information to cut a phenolic resin prototype using
The courageous story of recovering cancer victim Lance SurfCAM. Then the prototype was taken to Texas A&M
Armstrong centered the world’s attention on the U. S. Postal University for wind tunnel testing.
Service team in the 2000 Tour de France® bicycle road race. The test was conducted by aeronautical engineer John
Could Armstrong repeat his win and wear the yellow jersey Cobb and Cusack, with Armstrong riding the experimen-
again? Not only did he emerge victorious from the Tour de tal model in the tunnel. Variations were tried by adding
France, but just a month later he captured a bronze medal at clay to the model, but the original prototype delivered the
the Sydney, Australia, Summer Olympics™. best performance. “We nailed it right off the bat,” said
You might think the bicycle a champion like Armstrong Sagan. “We did make more changes later to improve the
rides would take a long time to develop, with a team of engi- lateral stiffness, but we had such a high confidence level in
neers puzzling over the design, tweaking and re-tweaking our digital model that we didn’t feel the need to make an-
time after time. The USPS Team Time Trial carbon fiber other prototype and could proceed directly to tooling. It
bike, made by world class bicycle manufacturer, Trek® really was a concept to victory.”
Bicycle, moved from initial concept to finished product in
just seven months. “That’s a first,” said Michael Sagan, In- About the Bike
dustrial Designer of Trek’sAdvanced Concept Group. “Nor- The USPS Time Trial bike frame is made of Optimum
mally it takes 12 to 14 months to complete a project like this.” Compaction Low Void (OCLV) carbon, a compressed,
super-light fiber. OCLV minimizes air pockets and max-
A Single Prototype imizes strength. The only thing close to it is a fighter
Sagan believes Trek was able to achieve the dramatically aircraft wing. The frame features an aerodynamic down-
fast turnaround in large part because the company had the tube, a steeper seat tube, and flared chain stays for a
right people and the right computer tools. Trek has been power-generating and wind-splitting riding position.
using Alias|Wavefront™ Studio™ for the past five years, The complete design results in a bike that is not only
and for this project the company moved to an NT system fast, light and strong, but also more comfortable for the
and paired it with the latest release of Studio. rider.
336